Fixture exchange rail system and method of use

ABSTRACT

A fixture exchange rail system is provided having first and second fixture assemblies movably mounted with respect to respective first and second stationary rails. A movable rail is disposed substantially adjacent to, and movable between, the first and second stationary rails. The movable rail is sufficiently configured to selectively receive the first and second fixture assemblies thereon. A method of operating a workstation having a fixture exchange rail system operable to enable work on a workpiece is also provided including the steps of: A) determining the style of workpiece present at the workstation; B) aligning a movable rail with one of a first and second stationary rail having a respective first and second fixture assembly mounted thereto corresponding to the style of workpiece; and C) moving the fixture assembly corresponding to the style of workpiece from the stationary rail to the movable rail.

CLAIM OF PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 11/552,154, filed on Oct. 24, 2006, now U.S. Pat. No. 7,992,276to Kussmaul, which is hereby incorporated by reference in its entirety,and to which priority is claimed herein.

TECHNICAL FIELD

The present invention relates to overhead tool or fixture rail systemsfor workstations and a method of using same.

BACKGROUND OF THE INVENTION

Overhead tool or fixture rail systems are frequently utilized inmanufacturing plants having assembly lines. The overhead fixture railsystems are typically arranged in parallel with the assembly line. Theseoverhead fixture rail systems are utilized for hanging tools or fixturesthat are required at a given workstation for the use of the productionline workers in assembling a workpiece. Modern assembly line designstypically require provisions for the assembly of more than one type ofworkpiece on the same assembly line. As such, many different types oftools or fixtures are typically hung from a single overhead fixture railsystem. This may lead to operator confusion over which tool to use for agiven style of workpiece. Additionally, the operator will be required tomove the additional tools or fixtures along the rail system in order toposition the tool or fixture required for the particular style ofworkpiece.

SUMMARY OF THE INVENTION

A fixture exchange rail system is provided having a first fixtureassembly movably mounted with respect to a first stationary rail and asecond fixture assembly movably mounted with respect to a secondstationary rail. A movable rail is disposable substantially adjacent tothe first and second stationary rails. The movable rail is movablebetween the first and second stationary rails and is sufficientlyconfigured to selectively receive the first and second fixtureassemblies thereon.

A method of operating the fixture exchange rail system of the presentinvention is also provided. The method includes the steps of: A)determining the style of workpiece present at the workstation; B)aligning a movable rail, either manually or automatically, with one of afirst and second stationary rail having a respective first and secondfixture assembly mounted thereto corresponding to the style ofworkpiece; and C) moving one of the respective first and second fixtureassembly corresponding to the style of workpiece from the first andsecond stationary rail to the movable rail.

The above features and advantages and other features and advantages ofthe present invention are readily apparent from the following detaileddescription of the best modes for carrying out the invention when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of a portion of an assembly lineillustrating a workstation incorporating a fixture exchange rail systemof the present invention; and

FIG. 2 is an illustration, in flowchart form, of a method of operatingthe fixture exchange rail system of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, there is shown a portion of a production orassembly line 10. The assembly line 10 includes a workstation 12incorporating a fixture exchange rail system 14 of the presentinvention. The workstation 12 is sufficiently configured to receive aworkpiece 16, such as a partially assembled vehicle, as shown in FIG. 1.The workpiece 16 is guided along the assembly line 10 by a plurality oftracks 18.

The fixture exchange rail system 14 includes a first, second and thirdstationary rail 20A, 20B, and 20C, respectively, and a movable rail 22.The movable rail 22 is disposed adjacent and movable with respect to thefirst, second, and third stationary rails 20A, 20B, and 20C in thedirection of arrow 24, i.e. substantially parallel to the workpiece 16.The movable rail 22 is suspended by a plurality of tracks 26, while thefirst, second, and third stationary rails 20A, 20B, and 20C aresuspended by a plurality of support members 28.

First, second, and third fixture assemblies 30A, 30B, and 30C aremounted to a respective one of the first, second, and third stationaryrails 20A, 20B, and 20C and are slidable within channels 32 in thedirection of arrows 34. Each of the first, second, and third fixtureassemblies 30A, 30B, and 30C include a respective first, second, andthird tool or fixture 36A, 36B, and 36C each suspended from theirrespective stationary rail 30A, 30B, and 30C by balancers 38. Thoseskilled in the art will recognize that balancers 38 are operable toreduce the apparent weight of the fixtures 36A, 36B, and 36C, therebyreducing operator fatigue. Additionally, the balancers 38 may beoperated by pneumatic force, spring tension, etc. while remaining withinthe scope of that which is claimed.

The first, second, and third fixture assemblies 30A, 30B, and 30Cfurther include a connector member 40, while a connector member 42 ismounted with respect to the moveable rail 22. The connector members 40and 42 taken together form a connector mechanism 44 operable toselectively connect the first, second, and third fixture assemblies 30A,30B, and 30C with the movable rail 22. The first, second, and third toolor fixture 36A, 36B, and 36C are actuated pneumatically via an air hose46.

Clamping members 48 are provided respectively on each of the first,second, and third stationary rails 20A, 20B, and 20C. The clampingmembers are operable to retain the movable rail 22 with respect to oneof the first, second, and third stationary rails 20A, 20B, and 20Cduring the transfer of the first, second, and third fixture assemblies30A, 30B, and 30C to and from the movable rail 22. Those skilled in theart will recognize that the clamping member 48 may be mounted to themovable rail 22, while remaining within the scope of that which isclaimed. The clamping members 48 are controlled by a controller 50.Additionally, the controller 50 operates to position the movable rail 22with respect to a selected one of the first, second, and thirdstationary rails 20A, 20B, and 20C through a selectively actuatable stopmechanism 52.

Position sensors 54 are provided respectively on each of the first,second, and third stationary rails 20A, 20B, and 20C and operate toprovide a signal to the controller 50 to communicate the position of thefirst, second, and third fixture assemblies 30A, 30B, and 30C. It shouldbe noted that FIG. 1 illustrates the second and third fixture assemblies30B and 30C in the parked position, while the first fixture assembly 30Ais shown in the out of park position. A sensor 56 is preferably mountedwith respect to the assembly line 10. The sensor 56 operates tocommunicate to the controller 50 the type or style of workpiece 16currently at the workstation 12. In the preferred embodiment the sensor56 will operate using optical sensing techniques such as, for example,bar code scanning; however, those skilled in the art will recognizeother means of sensing the type or style of workpiece 16 while remainingwithin the scope of that which is claimed.

A sensor 58 is mounted on the movable rail 22 and operates to signalwhen the connector member 40 of one of the first, second, and thirdfixture assemblies 30A, 30B, and 30C has engaged the connector member 42mounted on the movable rail 22 thereby completing the connection of theconnector mechanism 44. The sensor 58 may be mounted with respect to theconnector member 42, but need not be. A drive device 60 is controlled bythe controller 50 and operates to selectively move the movable rail 22with respect to the first, second, and third stationary rails 20A, 20B,and 20C.

Referring to FIG. 2, and with continued reference to FIG. 1, anexemplary method of operating the fixture exchange rail system 14 of thepresent invention is represented in FIG. 2, in flowchart form, and isgenerally indicated at 62. The method 62 begins at step 64 and proceedsto step 66 where it is determined if each of the first, second, andthird fixture assemblies 30A, 30B, and 30C are in the parked position.This condition is sensed by the position sensors 54 and communicated tothe controller 50. If at least one of the first, second, and thirdfixture assemblies 30A, 30B, and 30C is not in the parked position themethod proceeds to step 68 where they are manually parked; the method 62then proceeds to step 70. Alternately, if the first, second, and thirdfixture assemblies 30A, 30B, and 30C are in the parked position, themethod 62 proceeds from step 66 to step 70.

At step 70, a determination is made as to the style or type of theworkpiece 16. This information is sensed by the sensor 56 andcommunicated to the controller 50 as described hereinabove. In thepreferred embodiment, the controller 50 will command the drive device 60to move the movable rail 22 to one of the first, second, and thirdstationary rails 20A, 20B, and 20C containing the respective first,second, and third fixture assemblies 30A, 30B, and 30C appropriate forwork on the type of workpiece 16 currently within the workstation 12, asindicated at step 72. The automatic movement of the movable rail 22 doesnot pose a safety concern since none of the first, second, and thirdfixture assemblies 30A, 30B, and 30C are mounted thereto. Upon reachingthe appropriate one of the first, second, and third stationary rails20A, 20B, and 20C, for example the first stationary rail 20A, thecontroller 50 will command the stop mechanism 52 to lock the movablerail 22 in position. At this point, the method 62 will proceed to step74 where the controller 50 commands the clamping member 48 to engage,thereby clamping the movable rail 22 with respect to the firststationary rail 20A.

Proceeding to step 76, the first fixture assembly 30A is moved from therespective first stationary rail 20A to the movable rail 22. Preferably,step 76 is accomplished manually to give the operator full control overthe movement of the first fixture assembly 30A, such that the firstfixture assembly 30A can be safely positioned overhead. The method 62then proceeds to step 78 where a determination is made as to whether thefirst fixture assembly 30A is connected to the movable rail 22 via theconnector mechanism 44. That is, a determination is made as to whetherthe connector members 40 and 42 are fully engaged. If the connectormembers 40 and 42 are not engaged, the method 62 moves to step 80 wherethe first fixture assembly 30A is moved further into engagement with themovable rail 22. The method then proceeds to step 82 where thecontroller 50 commands the clamping member 48 to unclamp the movablerail 22 from the first stationary rail 20A. At which point the movablerail 22 is free to translate with respect to the first, second, andthird stationary rails 20A, 20B, and 20C. The method 62 then proceeds tostep 84.

At step 84, the movable rail 22, and therefore the first fixtureassembly 30A is positioned substantially adjacent to the workpiece 16thereby allowing the first fixture assembly 30A to be operated, at step86, to effect work on the workpiece 16. Upon the completion of work onthe workpiece 16, the movable rail 22 is realigned with the firststationary rail 20A at step 88. Preferably, step 88 is performedmanually to give the operator control of the first fixture assembly 30A.Once aligned with the first stationary rail 20A, the method 62 willproceed to step 90 where the movable rail 22 is clamped in place as aresult of a command by the controller 50 to the clamping member 48. Oncethe movable rail 22 is clamped in place, the method 62 proceeds to step92 where the first fixture assembly 30A is moved from the movable rail22 to the first stationary rail 20A such that the first fixture assembly30A engages the position sensor 54 to signal to the controller 50 thatthe first fixture assembly 30A is in the fully parked position. Themethod 62 then proceeds to step 94 to begin the cycle again.

The fixture exchange rail system 14 of the present invention providesassembly line flexibility by accommodating multiple styles of theworkpiece 16, while maintaining ergonomically advantageous toolorganization. Additionally, by automatically determining the style ofworkpiece 16 and directing the movable rail 22 to the appropriate one ofthe first, second, and third fixture assembly 30A, 30B, and 30C,improper assembly and damage to the workpiece 16 caused by the use of animproper fixture assembly may be eliminated.

Additionally, although the foregoing description illustrates a fixtureexchange rail system 14 having first, second, and third stationary rails20A, 20B, and 20C, those skilled in the art will recognize thatadditional or fewer stationary rails may be employed for a givenworkstation 12 while remaining within the scope of that which isclaimed.

While the best modes for carrying out the invention have been describedin detail, those familiar with the art to which this invention relateswill recognize various alternative designs and embodiments forpracticing the invention within the scope of the appended claims.

The invention claimed is:
 1. A method of operating a workstation havinga fixture exchange rail system operable to work on a workpiece, themethod comprising: determining the style of the workpiece present at theworkstation; aligning a movable rail defining a third channel with oneof a first stationary rail defining a first channel and at least oneother stationary rail defining a second channel, said first stationaryrail having a first fixture assembly slidably mounted thereto and saidat least one other stationary rail having at least one other fixtureassembly slidably mounted thereto, wherein said first fixture assemblyand said at least one other fixture assembly correspond to said style ofworkpiece; and moving one of said first fixture assembly and said atleast one other fixture assembly corresponding to said style ofworkpiece from one of said first stationary rail and said at least oneother stationary rail to said movable rail.
 2. The method of claim 1,wherein said first fixture assembly is slidably movable from one to theother of said first channel of said first stationary rail and said thirdchannel of said movable rail when said first stationary rail and saidmovable rail are aligned; and wherein said at least one other fixtureassembly is slidably movable from one to the other of said secondchannel of said at least one other stationary rail and said thirdchannel of said movable rail when said at least one other stationaryrail and said movable rail are aligned.
 3. The method of claim 1,further comprising: positioning said movable rail such that said one ofsaid respective first fixture assembly and said at least one otherfixture assembly corresponding to said style of workpiece issubstantially adjacent to the workpiece.
 4. The method of claim 1,further comprising: clamping said movable rail with respect to said oneof said first stationary rail and said at least one other stationaryrail subsequent to aligning said movable rail with said one of saidfirst stationary rail and said at least one other stationary rail. 5.The method of claim 1, further comprising: selectively connecting afirst connector member of said movable rail to a second connector memberof one of said first stationary rail and said at least one otherstationary rail using a connector mechanism such that as said respectiveone of said first fixture assembly and said at least one other fixtureassembly is moving between said movable rail and said respective one ofsaid first stationary rail and said at least one other stationary rail,said first connector member and said second connector member of saidconnector mechanism are connected.
 6. The method of claim 1, whereinaligning said movable rail with said one of said first stationary railand said at least one other stationary rail is automatic.
 7. The methodof claim 1, wherein aligning said movable rail with said one of saidfirst stationary rail and said at least one other stationary rail ismanual.
 8. The method of claim 1, further comprising: realigning saidmovable rail with respect to said one of said first stationary rail andsaid at least one other stationary rail when operation of said one ofsaid respective first fixture assembly and said at least one otherfixture assembly corresponding to said style of workpiece is complete;and moving said one of said respective first fixture assembly and saidat least one other fixture assembly corresponding to said style ofworkpiece from said movable rail to said one of said first stationaryrail and said at least another stationary rail.
 9. The method of claim8, further comprising: clamping said movable rail with respect to saidone of said first stationary rail and said at least one other stationaryrail subsequent to realigning said movable rail with said one of saidfirst stationary rail and at least one other stationary rail.
 10. Themethod of claim 1, further comprising: selectively controlling thealigning of said movable rail with one of said first stationary rail andsaid at least one other stationary rail using a controller.
 11. Themethod of claim 1, further comprising: selectively controlling themoving of said movable rail between said first stationary rail and saidat least one other stationary rail using a controller.
 12. The method ofclaim 11, further comprising: sensing the position of said first fixtureassembly and said at least one other fixture assembly using at least onesensing device; and providing a signal to said controller to communicatethe position of said first fixture assembly and said at least one otherfixture assembly.
 13. The method of claim 12, further comprising:determining if each of said first fixture assembly and said at least oneother fixture assembly are not in a parked position prior to determiningthe style of workpiece present at the workstation; and moving each ofsaid first fixture assembly and said at least one other fixture assemblywhich are not in a parked position into a parked position prior todetermining the style of workpiece present at the workstation.
 14. Themethod of claim 11, further comprising: sensing said style of workpiecepresent at the workstation using a sensing device; and providing asignal to said controller to communicate said style of said workpiece.15. The method of claim 1, wherein at least one of said first fixtureassembly and said at least one other fixture assembly is pneumaticallyoperated.
 16. The method of claim 1, wherein at least one of said firstfixture assembly and said at least one other fixture assembly issufficiently connected to said at least one balancer to reduce theapparent weight of said at least one of said first and second fixtureassemblies.
 17. The method of claim 1, wherein the workstation isconfigured as a workstation of an assembly line.
 18. The method of claim1, wherein the workpiece is a vehicle.
 19. A method of operating afixture exchange rail system, the method comprising: determining if eachof a first fixture assembly and at least one other fixture assembly arenot in a parked position; moving each of said first fixture assembly andsaid at least one other fixture assembly which are not in a parkedposition into a parked position; determining the style of a workpiecepresent at a workstation substantially adjacent to the fixture exchangerail system; aligning a movable rail with one of a first stationary railand at least one other stationary rail, said first stationary railhaving a first fixture assembly slidably mounted thereto and said atleast one other stationary rail having at least one other fixtureassembly slidably mounted thereto, wherein said first fixture assemblyand said at least one other fixture assembly correspond to said style ofworkpiece; moving one of said first fixture assembly and said at leastone other fixture assembly corresponding to said style of workpiece fromone of said first stationary rail and said at least one other stationaryrail to said movable rail; wherein said first fixture assembly isslidably movable from one to the other of said first stationary rail andsaid movable rail when said first stationary rail and said movable railare aligned; and wherein said at least one other fixture assembly isslidably movable from one to the other of said at least one otherstationary rail and said movable rail when said at least one otherstationary rail and said movable rail are aligned.
 20. The method ofclaim 19, further comprising: selectively connecting a first connectormember of said movable rail to a second connector member of one of saidfirst stationary rail and said at least one other stationary rail usinga connector mechanism such that as said respective one of said firstfixture assembly and said at least one other fixture assembly is movingbetween said movable rail and said respective one of said firststationary rail and said at least one other stationary rail, said firstconnector member and said second connector member of said connectormechanism are connected.